JP3131803B2 - Method for manufacturing patterned molded body - Google Patents

Abstract

A patterned shaped article is produced on a given surface (21) by a method including the steps of disposing a partition body (10) on the given surface, temporarily fixing a plurality of cut pattern pieces (23, 24, 25) to the upper surface of the partition body or the upper surface of a mesh member (26) disposed on the partition body so that the cut pattern pieces are disposed adjacent to each other to constitute a pattern to be formed, unfixing one of the cut pattern pieces from a portion of the upper surface to which a pattern-course material (3, 4, 5) is to be supplied, supplying the pattern course material to the portion, repeating the unfixing and supplying steps until the partition body is filled with a prescribed amount of pattern-course materials, removing the partition body alone or together with the mesh member from the pattern-course materials, and allowing the pattern-course materials to set into the patterned shaped article on the given surface. <IMAGE>

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a patterned concrete molded product, a patterned artificial stone molded product, a sintered body of a patterned ceramic molded product, a patterned ceramic molded product, a pressed coating molded product, and a plastic molded product. The present invention relates to a method for producing a patterned molded article such as a molded food.

[0002]

2. Description of the Related Art The applicant of the present invention has proposed a method of forming a compact body in which cylindrical small sections of a fixed height are arranged adjacent to each other on a bottom plate serving as a reference plane of a mold for forming a molded body. Arrange material holders such as forest solids in which the standing pieces are densely forested, and supply and hold a plurality of types of dry powdery granular material in the cells of the material holders and the standing intervals of the standing pieces, Japanese Patent Application No. 2-260433 and Japanese Patent Application No. 3-1465 describe a method for manufacturing a molded body with a pattern for expressing a pattern by integrally solidifying the pattern material.
No. 55, No. 273587, No. 273588, and Japanese Patent Application Nos. 4-73022 and 73023.

[0003]

In order to supply each pattern material to the cells in a densely packed cell, a plurality of patterns to be supplied are supplied with a mask which is the same size as the mold and has only a supply portion for the pattern material. By preparing a number corresponding to the material, using each mask, and supplying a predetermined pattern material, it can be represented almost exactly, but the number of pattern materials to be supplied and the formwork The same size mask is required, and it takes time to prepare and store the mask. Further, after supplying the pattern material using one mask, when removing the mask, the supplied pattern material overflows to the adjacent unsupplied or supplied pattern portion, or the pattern material remaining on the mask may be removed. Similarly adjacent unsupplied,
Alternatively, the pattern may be damaged by spilling on the supplied pattern portion.

[0004]

According to the present invention, the molding for solidifying a plurality of pattern materials integrally is performed in accordance with the above-mentioned prior proposal. However, in order to solve the above-mentioned problems caused by supplying each pattern material. A plurality of types of dry powder and granular pattern material are supplied and held in the cell dense body on the reference surface, and the pattern material is solidified together to form a patterned molded body that expresses the pattern. In the manufacturing method, each time a plurality of pattern pieces cut in accordance with the pattern to be expressed are temporarily fixed on the upper surface of the cell dense body to close the upper surface of the cell dense body, and each time a different type of material is supplied, It is characterized in that, of the plurality of pattern pieces closing the upper surface of the dense body, the pattern piece closing the upper surface to which the pattern material is to be supplied is peeled off from the upper surface of the cell dense body to supply the pattern material to the cell dense body. And Then, the pattern piece peeled off from the upper surface of the cell dense body to supply the pattern material is, after the supply of the pattern material, the upper surface of the cell dense body peeled until the supply of another type of pattern material to the cell dense body is completed. It is preferable to temporarily fix the same as before.

[0005]

FIG. 1 shows an example of a molded article formed according to the present invention, which has a pattern layer 1 on a surface expressing a pattern. Pattern layer 1
There is an integral backing layer 2 on the back side of this, but this backing layer 2 may be omitted. When the backing layer 2 is provided integrally, the backing layer 2 may be formed as described in the preceding proposal. The pattern of the pattern layer 1 is represented by three types of pattern materials: a white pattern material 3 representing snow at the top of the mountain, a brown pattern material 4 representing the foot of the mountain, and a sky blue pattern material 5 representing the sky.

FIG. 2 shows a mold having a cell dense body 11 for forming the molded body of FIG. 1 by the method of claim 1 and a bottom plate 22 serving as a reference surface 21 for mounting the cell dense body. Frame 2
0, pattern pieces 23, 24, 25 for individually supplying the pattern materials 3, 4, 5 to the cell dense body 11, and a net material 26 for supporting the pattern pieces 23, 24, 25 are shown. . The mesh material 26 may not be used as described later. As for the pattern pieces, a pattern piece 23 for supplying the white pattern material 3 to the top of the mountain, a pattern piece 24 for supplying the brown pattern material 4 to the bottom of the mountain, and a sky blue pattern material 5 to the sky are provided. And a pattern piece 25 for it. Then, the three pieces of pattern are temporarily fixed and adjacent to each other on the net material 26 so as to be the same as the pattern to be expressed. The mesh material 26 can drop dry powder and granular pattern materials 3, 4, and 5 to be supplied from the mesh.

In order to supply each pattern material to the cell dense body 11 in order to form a molded body, the cell dense body 11 is placed on a bottom plate of a mold, and a pattern piece is placed on the upper surface of the cell dense body 11. 2
For example, if the net material 26 having the temporary fixing 3, 24, 25 is temporarily fixed and the white pattern material 3 representing the snow on the peak is supplied, only the pattern piece 23 for the peak is used as shown in FIGS. The white pattern material is peeled off from the mesh material, and the white pattern material is supplied to the cells of the cell dense body through the mesh portion of the mesh material 26 exposed. As a result, the white pattern material does not enter other parts of the cell. Next, in order to supply a sky-colored pattern material representing the sky, the peeled-off peak pattern pieces 23 are temporarily fixed to the net material, and the sky pattern pieces 25 are peeled off from the net material, thereby being exposed. Similarly, the sky blue pattern material is supplied only to the empty portion through the mesh portion of the mesh material. In addition, in order to supply a brown pattern material representing the foot of the mountain, only the pattern piece 24 for the foot of the mountain is peeled from the net material, and the other pattern pieces 23 and 25 are temporarily fixed to the net material. In this way, after the supply of all the pattern materials, the pattern pieces 2 together with the net material 26 are obtained.
3, 24, 25 are removed, and the pattern material supplied to the cell dense body is humidified and solidified integrally, or the backing layer 2 is laminated and solidified together with the backing layer. In the case described above, the peeled pattern piece was temporarily fixed to the net material as before, but the pattern piece may be disposable and left peeled. For example, in FIG.
When the finished surface of the molded body is in contact with the mold bottom plate, it is only necessary to worry that the supplied pattern material is spilled on the adjacent unsupplied pattern part and damages the pattern, and the pattern piece is disposable, It is not necessary to temporarily fix the cell back to the densely packed cell or the net. In the case where the finished surface of the molded body is on the side where the pattern pieces are in contact, it is desirable to temporarily fix the pattern pieces once peeled back to the original state, so that the finish is beautifully finished.

Since the mesh material 26 is not always necessary as described above, when the mesh material is not used, the pattern pieces 23, 2
4 and 25 are temporarily fixed directly on the upper surface of the cell dense body 11 so as to be adjacent to each other in a pattern to be expressed, and a pattern piece is selected according to the pattern material to be supplied and peeled off from the upper surface of the material holder. Should be supplied.

If the cell dense body 11 is made of a material that dissolves the pattern material with moisture or the like that humidifies the pattern material, it is dissolved as it is, and if it is made of a non-dissolved material, the pattern material is completely dissolved as described in the prior proposal. Remove from pattern layer 1 before it hardens. In order to remove the cell dense body 11 and to integrate the backing layer 2 with the pattern layer 1, it is preferable that the peripheral frame 20 'of the mold 20 and the bottom plate 22 be separable. Further, in order to solidify the pattern layer 1 integrally with the existing concrete surface or the like as a reference surface, the cell dense body 11 is placed on the reference surface.
Is placed on the upper surface of the cell dense body via the net material 26,
Alternatively, the pattern pieces 23, 24, and 25 may be temporarily fixed without intervening, and similarly, various pattern materials may be supplied by peeling off the pattern pieces destined for one, and solidified together, or reversed and solidified integrally. .

[0010] The dry pattern material for producing the molded article by the method of the present invention may be any of water, oil, lubricating binder, solvent, hardener and plasticizer even if it contains at least one of water, oil, Use a dry material that is not kneaded with any of the lubricating binder, solvent, hardener, and plasticizer and can be easily loosened and supplied onto the reference surface. Even if the backing material is dry, wet water, oil, lubricating binder, solvent, hardener,
A mixture kneaded with one or more plasticizers may be used, or other materials such as metal, wood, cement, glass, ceramics, etc., boards, paper, nonwoven fabric, woven fabric, plastic Sheets and the like can be used. When boards, sheets, or the like are used as the backing material, the boards, sheets, or the like become the reference plane. Further, a pattern material may be layered using various existing moldings as a reference surface to be integrated. As the above-mentioned various materials for manufacturing a molded article, different materials or different finishes such as colors, gloss, and textures are used depending on the molded article to be produced.

[0011] The dry pattern material for producing a concrete molded body includes cement powder or resin alone,
Alternatively, a main component is a mixture thereof, and further a mixture obtained by adding a pigment or a fine aggregate thereto. In addition, the backing material is mainly composed of cement powder or resin alone or a mixture thereof, and further a mixture obtained by adding fine aggregate thereto, and, if necessary, any of pigment, coarse aggregate and various fibers. A mixture containing one or both of them may be as dry as the pattern material, or may be a wet one such as ready-mixed concrete kneaded with water or the like.
Wood chips may be used as aggregates or fine aggregates for both the pattern material and the backing material, if necessary, or granulated or crushed granite or marble, slag, fine particles that reflect light, inorganic hollow such as shirasu balloon, etc. Mixing powders and granules of bodies and ceramics, powders and granules of new ceramics, powders and granules of metals and other minerals, and mixing with setting and hardening accelerators, waterproofing agents, swelling agents and other admixtures Sometimes. The above-mentioned various fibers are metal fibers, carbon fibers, synthetic fibers, glass fibers and the like. Then, in order to solidify each material integrally in the mold, etc., put all the materials in the mold, etc. and then add the required amount of water or the like, but when using the wet backing material together In addition, the amount of water added is reduced in consideration of the moisture oozing out of the backing material. Also, other backing materials,
For example, boards such as metal, wood, cement, glass, and porcelain, or sheets such as paper and nonwoven fabric may be integrally solidified. Also, a patterned asphalt concrete or the like can be made using a heat-fusible material such as asphalt.

[0012] The dry pattern material and the backing material for producing the artificial stone molded body include rock particles, ceramic particles, new ceramic particles, glass particles which are not kneaded with a hardening agent such as cement powder and water. Plastics grains, wood chips,
A mixed aggregate containing one or more kinds of particles such as metal particles and containing a pigment as necessary is used. And, in addition to the cement powder and water described above, the cement powder, resin and water,
Or resin and water or solvent, or those mixed with rocks, ceramics, new ceramics, glass, plastics, or fine powder consisting of one or more of them, and containing pigments and colorants as necessary If necessary, various fine powders or fine particles, various fibers, various admixtures and various additives may be mixed. In addition, the above-mentioned various fine powders or fine particles are slag and fly ash, fine particles and other substances that reflect light, and various fibers are metal fibers, carbon fibers, synthetic fibers,
Various admixtures and additives, such as glass fiber, include anti-shrinkage agents, setting and hardening accelerators, retarders, waterproofing agents, swelling agents,
Water reducing agent, fluidizing agent and the like. Water, a solvent, a surface treatment agent or the like may be sprayed or immersed in the mixed aggregate, if necessary, in order to improve the adhesion with the curing agent. Then, in order to solidify each material integrally in a mold or the like, the hardener may be spread between aggregates by vacuum suction or the like after putting all the materials in the mold or the like, A mixture of an aggregate and a curing agent in advance may be used. Further, it may be layered on other backing materials, for example, boards such as metal, wood, cement, glass, and porcelain, or sheets such as paper, non-woven fabric, woven fabric, and plastics, and may be integrally solidified.

[0013] The sintering base for the ceramic molded body and the dry patterning material for producing the ceramic molded body include clay, rock or glass powder or granules, new ceramic powder or granules, and powder glaze. More than species, or a mixture of these and pigments and colorants as the main component, even if it contains water or lubricating binder from absolutely dry, it is not kneaded with water or lubricating binder and can be easily loosened and supplied Things.
The backing material is mainly composed of one or more of clay, rock or glass powder or granules, new ceramic powder or granules, or a mixture of these and a pigment or colorant, and is used for finishing the above-mentioned pattern. The material differs in color, luster, texture, etc., and may be a dry material like the pattern material or a wet material kneaded with water or a lubricating binder. In addition, if necessary, both the pattern material and the backing material may be mixed with substances such as inorganic hollow bodies such as shirasu balloons, crushed or crushed ceramics, metal or other mineral powders or granules, or various foams. Agents, glidants, fining agents, lubricants, binders, adhesion promoters and other additives may be mixed.
Then, in order to solidify each material integrally in the mold, etc., all the materials are put in the mold, etc., or as it is, or a necessary amount of water or a lubricating binder is added, plasticity is given, and pressure is applied. Then, as a base material, sintering is performed, or all the materials are put into a mold such as a refractory setter, and then heated and melted or fused. Alternatively, a pattern material is layered on a ceramic plate such as a metal plate, a glass plate, and a porcelain, and is heated and melted or fused to be integrated with the plate.

The dry pattern material for producing a press-coated molded product is various powder paints, and the backing material 2 'is a board such as metal, wood, cement, ceramics or the like. And the like. Various powder coatings include acrylic resin, polyester resin,
Acrylic-polyester hybrid resins, fluororesins and other resins to which a pigment or a coloring agent is added, and the like are listed. Then, to solidify each material integrally, a pattern material is layered on the backing material boards etc., heated, melted,
Fused, baked and integrated with boards and the like. Pressurization may be performed as necessary when integrated. With this method, a press-coated board can be obtained.

A dry pattern material for producing a plastic molded body is mainly composed of various plastic powders or granules, or a mixture of these with a pigment or a colorant,
Even if it contains a plasticizer or solvent, etc., it is not kneaded with the plasticizer or solvent, etc., and can be easily loosened and supplied. Use what has been kneaded and the like.
Various plastic powders or granules include polyethylene, nylon, polypropylene, polycarbonate, acetal, polystyrene, epoxy, vinyl chloride, natural rubber, synthetic rubber, ABS, PPO, EVA, fluoroplastics and other thermoplastic and thermosetting materials. Resins. still,
A foaming agent, an antioxidant, a heat stabilizer, a crosslinking agent and other various additives are added to both the patterning material and the backing material as necessary. Then, in order to solidify the respective materials integrally, they are heated and melted or fused while being pressurized as necessary, so as to be integrated. By this method, a molded article of patterned styrofoam or a patterned plastic bath can be manufactured. In this case, further layered on other materials, for example, metal, wood, cement, ceramics and other boards or paper, non-woven fabric, woven fabric, plastics and other sheets,
It may be one.

Dry pattern materials for producing confectionery and other molded foods include one or more kinds of wheat, rice, potato, red beans, corn, sugar powder or granules, or seasonings and spices. The main component is a mixture that contains oil and water, but is not kneaded with oil or water and can be easily loosened and supplied. Use what has been mixed. In addition, an expanding agent and other additives are added to both the pattern material and the backing material as necessary. And
To solidify each material together in a mold, etc., put all the materials in a mold
Plasticity is imparted, depressurized and demolded, and this is used as a base, and then baked, or all the materials are put into a mold and baked as one. By this method, various types of baked goods with a pattern can be manufactured. Also, a chocolate with a pattern or the like can be made by using a heat-meltable material such as chocolate.

In any of the moldings, if vibration is applied during the supply of the material, the movement of the granular material becomes smooth. Further, the boundary of the pattern material can be disturbed by a brush, an air jet, a water jet, or the like, and the pattern can be blurred.

Further, at the time of molding, a surplus water, oil, lubricating binder, plasticizer and solvent in the material can be removed by laying a nonwoven fabric or other water-absorbing or oil-absorbing mat on a reference surface or a pattern layer. Absorbed by the mat or excess water in some of the material,
Oils, lubricating binders, plasticizers and solvents can be replenished to other parts where it is deficient, making the water, oil, lubricating binders, plasticizers and solvents throughout the molded body uniform. This also reduces the water (auxiliary): cement (resin) ratio on the surface, thereby improving the strength of the compact. Further, when the air permeable mat is used for pressure molding, deaeration is assisted and a dense molded body can be formed. In addition, when hardening, one or both of the pattern layer and the backing layer are vibrated or pressurized to be dense and the strength can be improved. Furthermore,
Various long fibers and short fibers can be inserted between the pattern layer and the backing layer, or wire mesh or reinforcing steel can be inserted to reinforce.For the backing layer, molded articles by extrusion or extrusion, By using boards and sheets, it is possible to cope with molded articles for various uses such as architectural panels, boards, wall sheets and tiles. Alternatively, the reference surface may be formed on an existing concrete molded product, for example, and a pattern layer may be superimposed thereon and solidified integrally with the existing one.

By using a deformable mat as a reference surface, or a deformable mat for part or all of the mold after supplying the granular material, a finished surface such as a curved surface other than a flat surface can be produced.

[0020]

As is clear from the above, in the present invention, a plurality of pattern pieces cut in accordance with the pattern to be expressed are temporarily fixed on the upper surface of the cell densely packed body and adjacent to each other, and the pattern is manually adjusted according to the pattern material to be supplied. In order to supply the predetermined pattern material to the cell dense body by removing the pattern pieces, the size of all the pattern pieces adjacent to each other is the same size as the pattern layer of the molded body, so that no trouble is required for preparation and storage . Further, when the pattern material is removed and the pattern material is supplied, the other pattern pieces are prevented from entering another adjacent pattern portion, so that the pattern is not damaged.

[Brief description of the drawings]

FIG. 1 is a perspective view of a molded article having a pattern layer molded according to the present invention.

FIG. 2 is a perspective view showing a pattern piece, a cell dense body, and a mold for carrying out the method of claim 1;

FIG. 3 is a plan view showing a state in which one of the pattern pieces is removed and a pattern material is supplied.

FIG. 4 is a cross-sectional view taken along line AA of FIG.

[Explanation of symbols]

 Reference Signs List 11 Cell dense body 20 Formwork 21 Reference plane 23 Pattern piece 24 Pattern piece 25 Pattern piece 26 Mesh material

Continuation of the front page (51) Int.Cl. ⁷ Identification symbol FI B29C 43/34 B29C 43/34 (56) References JP-A-4-140104 (JP, A) JP-A-50-30918 (JP, A) JP-A-4-105903 (JP, A) JP-A-1-1000081 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B28B 1/14-1/16 B28B 3/02 B28B 7/00-7/46 B29C 43/20 B29C 43/34

Claims (2)

(57) [Claims] 1. A method for producing a pattern-formed molded body that expresses a pattern by supplying a plurality of types of dry powder and a granular pattern material to a cell dense body on a reference surface and holding the dry powder and a granular pattern material. In the above, each time a plurality of pattern pieces cut according to the pattern to be expressed are temporarily fixed on the upper surface of the above-mentioned cell dense body to close the upper surface of the cell dense body and supply a different type of material, The method is characterized in that, of the plurality of pattern pieces covering the upper surface of the cell, the pattern material covering the upper surface to which the pattern material is to be supplied is peeled off from the upper surface of the cell dense body to supply the pattern material to the cell dense body. A method for producing a patterned molded body. 2. The method according to claim 1, wherein the pattern pieces peeled off from the upper surface of the densely packed cells for supplying the pattern material are provided with another type of pattern after the supply of the pattern material. A method for producing a patterned molded body, characterized in that the molded body with a pattern is temporarily fixed to the upper surface of the cell dense body that has been peeled off until the supply of the material to the cell dense body is completed.